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 Preceramic composition containing silicon based powder

Details
Inventors: Niebylski, Leonard M.;
Assignee: Ethyl Corporation (Richmond, VA)
Primary Examiner: Nelson; Peter A.
Assistant Examiner:
Attorney, Agent or Firm: Hogan; Patricia J.

Preceramic compositions which have particular utility in providing protective ceramic coatings on carbonaceous and other normally oxidizable substrates are prepared by dispersing about 0.4-3.0 parts by weight of a ceramic powder selected from silicon carbide, silicon nitride, and mixtures thereof with one another and/or with up to about 90% by weight of (1) a metal boride or (2) a mixture of a metal boride and zirconium metal in one part by weight of a polysilazane.

DETAILED DESCRIPTION The polysilazane used in the practice of the invention may be any polysilazane that is soluble in common organic solvents, such as aliphatic or aromatic hydrocarbons or dialkyl or alicyclic ethers; and it may be, e.
g.
, a polysilazane of Seyferth et al.
-I, -II, -III, -IV, or -V or Arai et al.
, the teachings of all of which are incorporated herein by reference.
However, it is preferably a polysilazane of the type taught by Seyferth et al.
-II, i.
e.
, a polysilazane prepared by reacting an organodihalosilane, such as methyldichlorosilane, with ammonia and polymerizing the ammonolysis product with a basic deprotonation catalyst, such as potassium hydride.
Although the ceramic powder may be any of those taught above, it is preferably silicon carbide or a silicon carbide-containing mixture of powders.
A particularly preferred form of silicon carbide, especially when it is used primarily to provide heat or abrasion resistance, is alpha-silicon carbide.
As already mentioned, the ceramic powder may include up to 90% by weight of a metal boride, such as the borides or silicon, hafnium, titanium, niobium, zirconium, and the rare earth metals, or a mixture of a metal boride and zirconium metal.
When included, this optional component usually constitutes about 20-90%, preferably 20-50% by weight of the total ceramic powder; and it is preferably a silicon boride, i.
e.
, silicon tetraboride and/or silicon hexaboride.
It is preferred that the ceramic powder have an average particle size of about 0.
1-40 micrometers, most preferably about 0.
1-10 micrometers, to facilitate the formation of a homogeneous dispersion.
However, finer or coarser particles are also utilizable.
The amount of ceramic powder used may be anywhere in the range of about 0.
4-3.
0 parts, preferably about 0.
5-1.
5 parts per part by weight of the polysilazane, although the smaller amounts are apt to be preferred when the powder is employed to provide heat or abrasion resistance, while the larger amounts are preferred when the objective of incorporating the powder is primarily to provide oxidation resistance



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